System and method for lens alignment and bonding

ABSTRACT

A system for securing an infrared camera lens in optical alignment with a multiple pixel infrared camera sensor, comprising: a computer-controlled robotic arm to adjust a relative position of the camera sensor and the camera lens so as to bring the lens into an ideal lens position with respect to the camera sensor, wherein the ideal lens position is determined based on focus sharpness over at least a plurality of pixels at the camera sensor of at least one projected calibration target as focused by the camera lens on the camera sensor; and at least one computer-controlled welder that is adapted to perform welding together of at least two metal parts of the camera after the camera lens is positioned by the robotic arm in the ideal lens position with respect to the camera sensor such that the camera lens is permanently maintained in the ideal lens position.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit as a continuation of U.S. applicationSer. No. 17/384,477 filed on Jul. 23, 2021, which in turn claims benefitfrom 1) U.S. provisional application No. 63/156,611 filed on Mar. 4,2021, 2) as a continuation-in-part of U.S. application Ser. No.17/323,414 filed on May 18, 2021, now U.S. Pat. No. 11,252,316, which inturn is a continuation of U.S. application Ser. No. 16/699,894 filed onDec. 2, 2019, now U.S. Pat. No. 11,025,807, and 3) as acontinuation-in-part of U.S. application Ser. No. 17/154,695 filed onJan. 21, 2021, now U.S. Pat. No. 11,356,585, which is acontinuation-in-part of U.S. application Ser. No. 16/699,894 filed onDec. 2, 2019, now U.S. Pat. No. 11,025,807. The contents of all of theforegoing applications are hereby incorporated by reference.

TECHNICAL FIELD

The present disclosure relates generally to camera lens calibration, andmore specifically to the initial alignment and calibration of infraredcamera lenses.

BACKGROUND

As sensor-based technology has improved dramatically in recent years,new uses for sensors have become possible. In particular, cameras havebecome widely utilized for various applications, including advanceddriver assistance systems (ADAS) and autonomous vehicle systems. Onetype of camera that may be utilized in these applications is a thermalinfrared camera. The infrared spectrum lies outside of the visible lightrange and consists of a near infrared section (NIR) with wavelengths of0.75-1 micrometers (μm); a short wavelength infrared section (SWIR) withwavelengths of 1-3 μm; a medium wavelength infrared section (MWIR) withwavelengths of 3-5 μm; and a long wavelength infrared section (LWIR)with wavelengths of 8-14 μm. Many thermal infrared (IR) cameras operatewithin the LWIR section to detect infrared energy that is guided to anIR sensor through the camera's lens. These IR cameras can be utilizedfor a variety of imaging applications including, but not limited to,passive motion detection, night vision, thermal mapping, health care,building inspection, surveillance, ADAS, and the like.

During the manufacture of an infrared camera, a lens should be attachedto the camera body, namely the element of the camera housing an infraredimage sensor. This attachment should be performed to exacting standards,as the lens must not only be placed at an ideal distance from thesensor, but in an ideal plane, since any minor shift or skewedpositioning will result in subpar or out of focus images. Therefore, thelens should be secured to the camera body with optimal positioning alongthe six degrees of freedom. Attaching a lens in such a precise mannermanually is not only ineffective, but difficult to replicate on aconsistent basis, let alone accomplish in an efficient manner. Further,even though robotic arms may be used to execute the attachment andreliably repeat the same movements from camera to camera, each lens andsensor may vary ever so slightly, requiring a unique and individualizedattachment for each pairing of a sensor and a lens, proving a difficulttask for a generic robot.

It would therefore be advantageous to provide a solution that wouldovercome the challenges noted above.

SUMMARY

A summary of several example embodiments of the disclosure follows. Thissummary is provided for the convenience of the reader to provide a basicunderstanding of such embodiments and does not wholly define the breadthof the disclosure. This summary is not an extensive overview of allcontemplated embodiments, and is intended to neither identify key orcritical elements of all embodiments nor to delineate the scope of anyor all aspects. Its sole purpose is to present some concepts of one ormore embodiments in a simplified form as a prelude to the more detaileddescription that is presented later. For convenience, the term “certainembodiments” may be used herein to refer to a single embodiment ormultiple embodiments of the disclosure.

Certain embodiments disclosed herein include a system for securing aninfrared camera lens in optical alignment with a multiple pixel infraredcamera sensor, including: a computer-controlled robotic arm adapted toadjust a relative position of the infrared camera sensor and theinfrared camera lens so as to bring the infrared lens into an ideal lensposition with respect to the infrared camera sensor, wherein the ideallens position is determined based on focus sharpness over at least aplurality of pixels at the infrared camera sensor of at least oneprojected calibration target as focused by the infrared camera lens onthe infrared camera sensor; and at least one computer-controlled welder,the at least one computer-controlled welder being adapted to performwelding together of at least two metal parts of the infrared cameraafter the infrared camera lens is positioned by the robotic arm in theideal lens position with respect to the infrared camera sensor such thatthe infrared camera lens is permanently maintained in the ideal lensposition.

Certain embodiments disclosed herein also include a method for securingan infrared camera lens in optical alignment with a multiple pixelinfrared camera sensor, including: adjusting a relative position of theinfrared camera sensor and the infrared camera lens bycomputer-controlled robotic arm so as to bring the infrared lens into anideal lens position with respect to the infrared camera sensor, whereinthe ideal lens position is determined based on focus sharpness over atleast a plurality of pixels at the infrared camera sensor of at leastone projected calibration target as focused by the infrared camera lenson the infrared camera sensor; and welding together, by at least onecomputer-controlled welder, at least two metal parts of the infraredcamera after the infrared camera lens is positioned by the robotic armin the ideal lens position with respect to the infrared camera sensorsuch that the infrared camera lens is permanently maintained in theideal lens position

Certain embodiments disclosed herein also include a method for securinga camera lens in optical alignment with a multiple pixel camera sensor,including: adjusting a relative position of the camera sensor and thecamera lens by computer-controlled robotic arm so as to bring the lensinto an ideal lens position with respect to the camera sensor, whereinthe ideal lens position is determined based on focus sharpness over atleast a plurality of pixels at the camera sensor of at least oneprojected calibration target as focused by the camera lens on the camerasensor; and welding together, by at least one computer-controlledwelder, at least two metal parts of the camera after the camera lens ispositioned by the robotic arm in the ideal lens position with respect tothe infrared camera sensor such that the camera lens is permanentlymaintained in the ideal lens position.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter disclosed herein is particularly pointed out anddistinctly claimed in the claims at the conclusion of the specification.The foregoing and other objects, features, and advantages of thedisclosed embodiments will be apparent from the following detaileddescription taken in conjunction with the accompanying drawings.

FIG. 1 is a schematic diagram of a system for optical alignment andcalibration of an infrared camera lens according to an embodiment.

FIG. 2A is a schematic diagram of a calibration target according to anembodiment.

FIG. 2B is an example screenshot of a multiple calibration targets asseen through a calibration system.

FIG. 3 is an example screenshot of multiple modulation transfer function(MTF) charts projected onto an image of the calibration targets aftercalibration has been completed.

FIG. 4 is an example flowchart illustrating a method for attaching andaligning an infrared camera lens according to an embodiment.

FIG. 5 is an example setup of an infrared lens alignment system andcuring light sources, according to an embodiment.

FIG. 6 shows an illustrative method for fixing the lens in the ideallens position by employing a welding process according to an embodiment.

FIG. 6A shows an illustrative method for fixing the lens in the ideallens position by employing a welding process according to an embodiment.

FIGS. 7A-7D shows various views of an illustrative arrangement of aninfrared camera having a lens body inserted into a camera body such thatthey may be permanently joined together in a fixed relationship usingwelding.

FIGS. 8A-8F shows various views of an illustrative arrangement of aninfrared camera having a lens body inserted into a camera body such thatthey may be permanently joined together in a fixed relationship usingwelding.

FIGS. 9A-9D shows various views of an illustrative arrangement of aninfrared camera having a lens body inserted into a camera body such thatthey may be permanently joined together in a fixed relationship usingwelding.

FIGS. 10A-10D shows various views of an illustrative arrangement of aninfrared camera having a lens body inserted into a camera body such thatthey may be permanently joined together in a fixed relationship usingwelding.

FIGS. 11A-11D shows various views of an illustrative arrangement of aninfrared camera having a lens body inserted into a camera body such thatthey may be permanently joined together in a fixed relationship usingwelding.

FIGS. 12A-12D shows various views of an illustrative arrangement of aninfrared camera having a lens body inserted into a camera body such thatthey may be permanently joined together in a fixed relationship usingwelding.

FIGS. 13A-13E shows various views of an illustrative arrangement of aninfrared camera having a lens body inserted into a camera body such thatthey may be permanently joined together in a fixed relationship usingwelding.

FIG. 14 shows a flow chart for an illustrative process by which a sensoris adjusted with respect to a lens in order to place the lens in theideal lens position.

FIG. 15 shows a robotic arm holding a lens body and illustrativewelders.

FIG. 16 shows robotic arm holding a lens body and a welder attached torobotic arm.

FIGS. 17A-17F shows various views of an illustrative arrangement ofportions of an infrared camera and manipulators by which the sensor ismanipulated so as to position the lens of the camera in the ideal lensposition and so that the sensor may then be permanently fixed intoposition using welding.

DETAILED DESCRIPTION

It is important to note that the embodiments disclosed herein are onlyexamples of the many advantageous uses of the innovative teachingsherein. In general, statements made in the specification of the presentapplication do not necessarily limit any of the various claimedembodiments. Moreover, some statements may apply to some inventivefeatures but not to others. In general, unless otherwise indicated,singular elements may be in plural and vice versa with no loss ofgenerality. In the drawings, like numerals refer to substantially likeparts through several views.

The terms glue and adhesive are used interchangeably herein.

FIG. 1 is a schematic diagram of a system 100 for optical alignment andcalibration of an infrared camera lens 120 according to an embodiment.The system 100 includes one or more collimators 150 placed directlyabove a lens 120, such as an infrared lens, to be used for lenscalibration. A lens support mechanism of the system 100 includes arobotic arm 140 configured to hold the lens 120 and manipulate itsposition relative to a camera body 110. In an embodiment, the roboticarm 140 is supported by a hexapod platform 145. In an exampleembodiment, the platform 145 is configured to move the robotic arm 140,and the lens attached thereto 120, in a predefined number (e.g., 6)degrees of freedom. In a further embodiment, the hexapod platform 145 isa Steward platform with a high-resolution kinematic system employingthree pairs of hydraulic, pneumatic, or electro-mechanical actuatorsconfigured to adjust the x, y, and z axes along with the pitch, roll,and yaw. This allows for precise adjustments to the positioning of therobotic arm 140 attached thereto and thus to the lens 120. In anembodiment, the hexapod is controlled by software executing on acomputer, or hardware, that is configured to adjust the hexapodaccording to readings from the collimators 150, as discussed furtherbelow. In such an embodiment, the hexapod, and hence the robot arm, arecomputer controlled.

The software is stored in a machine-readable media and shall beconstrued broadly to mean any type of instructions, whether referred toas software, firmware, middleware, microcode, hardware descriptionlanguage, or otherwise. Instructions may include code (e.g., in sourcecode format, binary code format, executable code format, or any othersuitable format of code).

The collimators 150 are optical instruments including a well correctedobjective lens with an illuminated calibration target at its focalplane. The emerging beam is a parallel, or collimated, beam, so that theimage of the calibration target is projected at infinity. In anembodiment, there are five collimators 150 positioned above the lens 120and the camera body 110 and are configured to output a calibrationtarget projection. The collimators 150 are positioned such that theoutput calibration target projection converges on the infrared sensorwithin the camera body 110, through the lens 120. The angled arrangementof the collimators is designed to define the whole area of an imagesensor according to the camera's apparent field of view (FOV). In anembodiment, a shutter mechanism (not shown) is placed between the lens120 and the collimators 150, such that the shutter can be opened andclosed as the position of the lens 120 is adjusted, to provide anefficient manner of calibrating the lens between various positions.

Each collimator 150 includes three main parts: a black body, a target,and a collimating lens system. The parts of the collimator 150 aredisposed within a structure of the collimator and are not shown in FIG.1 . In an embodiment, the black body is an electrically controlleddevice that is used as a highly thermally stable background radiationsource for the target. In an embodiment, it provides a difference of 10degrees relative to a room ambient temperature. The camera sensor ispositioned toward the black body, such that when the lens 120 is inplace, the image produced by the sensor contains a calibration targetwith a background of the black body. When in a properly calibratedposition, the projection of the calibration targets converge on theinfrared sensor of the camera 110 such that when the lens 120 is inplace, the MTF values are optimized for all of the calibration targets.The system 100 may include multiple black bodies positioned within theFOV of the sensor used as calibration targets for the lens. Thecalibration targets are further discussed below.

In an optional embodiment, one or more ultraviolet (UV) light sources170 are placed around the lens 120 and the camera body 110. An adhesivemay optionally be used to secure the lens 120 to the camera body 110,where the adhesive is only cured when exposed to UV light. Thus, theposition of the lens 120 can be freely adjusted until an ideal lensposition is determined for lens 120, as discussed herein below, at whichpoint the UV light sources 170 are used to cure the adhesive and fixlens 120 in place. In one embodiment the adhesive may be Dymax® 6-621GELUV adhesive. In a further embodiment, alternative curing mechanisms areused instead of a UV curing mechanism, such as visible light curing,temperature-based curing, chemical curing, and so on.

FIG. 2A is a schematic diagram of a calibration target 200 according toan embodiment. The target may include a black body designed to provide atemperature difference as a reference of thermal radiation, and reveal aportion of the black body arranged in a certain pattern that can berecorded by the sensor and analyzed by the image processing software. Inan embodiment, an example pattern includes the calibration target 200with a circular shape and a portion of the circular shape exposed toreveal a black body. For example, a wedge 210 having a specific angle,e.g., an angle of 104 degrees (90 degrees of a quarter circle, with anadditional 7 degrees 220 extending outward from each axis of the wedge)is shown. In an embodiment, the size of the wedges 210, e.g., the angleof the wedge, is adjustable, which allows for the control of the patternappearance, and supports a variety of different patterns to supportvarious application needs. The straight edges, set angle, and curvedouter perimeter of the wedge shape provide different useful referencepoints to assist in determining a sharp focus that indicates calibrationof the lens, i.e., that the lens is in the ideal lens position. Having 5calibration targets 200 placed at defined parts of the FOV of the lensallows for greater optimization of the lens position.

FIG. 2B is an example screenshot of multiple calibration targets 200 asseen by the camera through a calibration system. The calibration targets200 are positioned to maximize coverage of the image sensor area. In anembodiment, five calibration targets 200 are used, where one target isplaced toward each corner and one target is placed in the center of theframe. The calibration targets 200 are visible through a collimator,e.g., the collimator 150 of FIG. 1 . The five collimators may eachcontain one calibration target 200 and are positioned to fill the FOV ofthe camera and the image sensor area.

FIG. 3 is an example screenshot of multiple modulation transfer function(MTF) charts 300 projected onto an image of the calibration targets. AnMTF is a tool used to measure imaging quality, including the contrastand the resolution of an optical device. The MTF graph displays thecontrast as a function of spatial frequency. In an embodiment, themiddle of the image sensor detects higher resolution MTFs compared tothe extremities of the sensor. In an embodiment, each section of theframe that contains a calibration target 200 is provided with an MTFchart 300. The position of the lens is adjusted, e.g., by controllingthe hexapod 145 and robotic 140 holding the lens 120 of FIG. 1 , untileach of the MTF charts 300 is optimized. In an embodiment, software isused to analyze the local MTF responses in test images from the targetto provide feedback for controlling the hexapod 145 in order to adjustthe position of lens 120.

The calibration process includes a converging routine that uses the MTFchart 300 data as a metric in the determination of an optimal positionfor the lens, i.e., the ideal lens position with respect to the sensor,e.g., sensor 120. In an embodiment, the converging routine takes intoconsideration the measurements from five targets: one in the middle andone at each of the four corners of an image. In the shown example, theconverging routine determines an optimal position where for a spatialfrequency of 50, the received MTF value is approximately 0.2 for each ofthe MTF charts 300.

In an embodiment, the exact lens positioning 310, e.g., measuring inmillimeters and degrees from a point of reference, is determined andsaved for future reference.

FIG. 4 is an example flowchart 400 illustrating a method for attachingand aligning an infrared camera lens according to an embodiment.

At S410, an adhesive may be applied to a lens configured for an infraredcamera. The adhesive may be formulated to be set and cured when exposedto a curing catalyst, such as an ultraviolet (UV) light, a temperaturechange, a chemical reaction, laser light, and so on. In an embodiment,the lens is handled with a robotic arm, such that the adhesive isapplied to the circumference of the lens.

At S420, the lens, with the applied adhesive, is placed above the camerabody while still being held, e.g., by the robotic arm. Thus, thepositioning of the lens can still be adjusted by the robotic arm or ahexapod attached thereto, while the adhesive has not yet been cured.

At S430, the ideal lens position is determined based on calibrationtarget images and MTF charts associated with those targets, as discussedabove in connection with FIG. 3 . The position of the lens is adjustedbased on feedback from an MTF chart, such that the resolution andcontrast of the image from the camera upon which the lens is placed ismaximized in all image regions, e.g., in the four corner regions and acenter region with one region assigned to one calibration target. In anembodiment, if all of the MTF charts associated with each calibrationtarget images cannot be maximized in a single position, the positionthat produced the best resolution and contrast uniformly among all thecalibration target images is used. At the end of S430 the lens is in itsideal position. Moving the lens so as to adjust its position may beperformed by the robot arm under computer control using feedback fromthe camera sensor.

At S440, the position of the lens is moved from its ideal lens positionto a new position. The new, offset position is one that is determined tocompensate for adhesive shrinkage. Put another way, since the adhesiveshrinks as it is being cured, had the lens been left at its determinedideal position when the curing process is begun, the lens would moveaway from the ideal position by virtue of being pulled by the adhesiveas the adhesive shrinks while it cures. To compensate for suchshrinkage, the lens is moved, prior to curing to a position thatcompensates for such shrinkage, such that at the end of the curingprocess it is expected that the lens will end up back at its determinedideal position. The offset position, which is a function of theproperties of the particular adhesive employed, is determinableempirically or experimentally in a manner well known to those ofordinary skill in the art. Thus, the offset position to which the lensis moved is based on the ideal lens position and the properties of theparticular adhesive employed. Advantageously, instead of the lens beingmoved to a final position from its determined ideal lens position byshrinkage of the glue during curing, and so being improperly located,the final position of the lens after curing is substantially thedetermined ideal location because the lens was moved to the new, offsetposition prior to being cured.

At S450, the adhesive is cured and the lens is fixed in place. In anembodiment, curing may be accomplished by exposing the adhesive tointense UV light from multiple directions in order to ensure uniformcuring. In one embodiment, the adhesive is cured by exposure to UV lightfor 30 seconds from 4 UV LED sources, such as UV light sources 170 (FIG.1 ) positioned equally around the camera body, e.g., camera body 110(FIG. 1 ). In a further embodiment, curing is accomplished byalternative catalysts, such as a visible light source, a temperaturechange, a chemical reaction, laser light, and so on.

FIG. 5 is an example setup of an infrared lens alignment system andcuring lights, according to an embodiment. The robotic arm 140 holds thelens 120 above the camera body 110, which contains an infrared imagesensor (not shown). Multiple UV light sources 170, e.g., UV lightemitting diodes (LEDs), can be distributed around the lens 120 toprovide an even amount of light. The UV light causes a photochemicalprocess which hardens certain resins that may be used as an adhesive tokeep the lens 120 in the ideal lens position. In an embodiment, fourhigh-intensity spot curing LEDs operating on a 365 nm wavelength areused although it will be appreciated that other wavelengths may beemployed, e.g., depending on the adhesive employed. In a furtherembodiment, other curing techniques may be used, such as visible lightcuring, lasers, halogen or tungsten lights, and the like.

According to the disclosed embodiments, a method and system for placinga lens within a lens body, which refers to the holder within which thelens itself is disposed, and note that both were hereinabove simplyreferred to for convenience as “the lens”, e.g., lens 120 (FIGS. 1 and 4), into the ideal lens position with respect to a camera sensor andbonding the lens body to a thermal camera body are provided. In order tomaintain a good image quality, the lens' position should be accuratelyaligned and calibrated. In an embodiment, the alignment is performed byusing a 6 degree of freedom robotic arm and collimators projecting blackbody images onto the sensor. In an embodiment, while the alignmentmechanism and the process may be the same, as for example discussedabove, the bonding procedure is different.

FIG. 6 shows an illustrative method for fixing the lens in the ideallens position by employing a welding process according to an embodiment.At S610, a glue is applied to pre-fix the lens in a calibrated position,i.e., the ideal lens position. By pre-fixing it is meant to temporarilyhold the lens in position. However, since in this embodiment the glue isonly used, as an intermediate stage, the glue need not provide for astrong or a durable bond. The glue merely needs to be sufficient to holdthe lens in position once it is no longer being moved, e.g., after thelens has been moved to the ideal lens position. In other words, in oneembodiment, as part of step S610 the glue may be applied and then thelens is moved to the ideal lens position by the robotic arm, e.g., inthe manner set forth hereinabove, e.g., per step S430. The glue may beapplied radially along the lens body circumference and the lens body maybe inserted into the camera body, or vice versa. By doing so, of coursedepending upon the particular glue employed, glue shrinkage may notalter the lens's alignment and so would not cause movement of the lensalong the optical axis.

At S620, once the lens body is aligned with the camera body so that thelens is in the ideal lens position, the camera body and lens are bondedby curing the glue at least to a level sufficient to maintain therelative positional relationship between them when moving them togetheras a unit should such need to be done per optional step S630. Atoptional step S630, the camera assembly, i.e., the camera body and thelens which are now bonded together, may be removed out of the alignmentdevice and transferred into a device with a welding unit, e.g., a laserwelding unit. In an embodiment, the welding unit is computer controlled,i.e., controlled by software executing on a computer, or hardware, thatis configured to control the operation of the welding unit.

At S640, a welding process is performed by the welding unit in order topermanently attach by welding the camera body and the lens body so as tomake sure that the lens is maintained permanently in the ideal lensposition. When optional step S630 is not performed, the welding processof step S640 is performed at the same location at which the alignment ofthe lens body and camera body is performed. This may be achieved byadvancing a welder arm to the camera in the same location.

In one embodiment the welding may be performed only at a number ofpoints along the perimeter of the junction between the camera body andthe lens body. In such an embodiment, an extra step may be performed toseal the camera against moisture, e.g., application of a sealant alongthe perimeter. In another embodiment, the welding process can beperformed in a continuous fashion around the entire perimeter at theinterface of the camera body and the lens body. As such, the weldingscar will completely cover the lens-camera interface. In this case, noadditional sealing may be required.

At optional S650, it may be verified, e.g., for quality controlpurposes, if the camera body and lens body are still aligned such thatthe lens is in the ideal lens position, or whether the alignment haschanged during the welding process. If the camera is found to bemisaligned, a realignment process may be performed.

FIG. 6A shows an illustrative method for fixing the lens in the ideallens position by employing a welding process according to an embodiment.At S610A, the lens body is inserted into the camera body.

At S620A, the lens body is aligned with the camera body so that the lensis in the ideal lens position. The spatial relationship between the lensbody and the camera body is adjusted so that the lens is at the ideallens position. In one embodiment, this may be achieved by moving thelens body, the camera body, or both. Such movement may be performed byat least one robotic arm. In another embodiment the position of the lensbody with respect to the camera body may be controlled by one or moreadjustable supports. For example, set screws could be used to controlthe angle and height of the lens body with respect to the camera body.The method of aligning should be such that in the event that the camerabody and lens body assembly needs to be moved to a different location atwhich a welding unit is located, e.g., in optional step 630A, therelative positional relationship between them as established in step620A will be maintained. This may be achieved in one embodiment byemploying a few, e.g., three, spot welds sufficient to maintain therelative positional relationship between the lens body and the camerabody without fully welding them. At optional step S630A, the cameraassembly, i.e., the camera body and the lens which are now in arelationship such that the lens is in the ideal lens position which willbe maintained, may be removed out of the alignment device andtransferred into a device with a welder unit, e.g., a laser weldingunit.

At S640A, a welding process is performed by the welding unit in order topermanently attach by welding the camera body and the lens so as to makesure that the lens is maintained permanently in the ideal lens position.When optional step S630A is not performed, the welding process of stepS640A is performed at the same location at which the alignment of thelens body and camera body is performed. This may be achieved byadvancing a laser welder arm to the camera in the same location orhaving the laser welding arm at the same location. In an embodiment, thewelding unit is computer controlled, i.e., controlled by softwareexecuting on a computer, or hardware, that is configured to control theoperation of the welding unit.

In one embodiment the welding may be performed only at a number ofpoints along the perimeter of the junction between the camera body andthe lens body. In such an embodiment, an extra step may be performed toseal the camera against moisture, e.g., application of a sealant alongthe perimeter. In another embodiment, the welding process can beperformed in a continuous fashion around the entire perimeter at theinterface of the camera body and the lens body. As such, the weldingscar will completely cover the lens-camera interface. In this case, noadditional sealing may be required.

At optional S650A, it may be verified, e.g., for quality controlpurposes, if the camera body and lens body are still aligned such thatthe lens is still in the ideal lens position, as the alignment may havechanged during the welding process. If the camera is misaligned, arealignment process may be performed.

FIG. 7A shows an illustrative arrangement of an infrared camera having alens body inserted into a camera body such that they may be permanentlyjoined together in a fixed relationship using welding. In particular,shown in FIG. 7 is camera body 701 into which has been inserted lensbody 703. Lens body 703 includes lens 705 which is shown as merelyrepresentative for illustrative purposes only. Camera body 701 containsslotted cylindrical ring 707 which receives interior thereto lens body703. Slotted cylindrical ring 707 is effectively permanently attached tocamera body 701 using any method available, e.g., glue, welding,friction, or integrated formation, and may be considered as a part ofcamera body 701 given that such method of attachment is essentially notrelevant to the process of FIG. 6 or 6A for placing lens 705 into theideal lens position and then permanently attaching camera body 701 andlens body 703. Slotted cylindrical ring 707 has a base 729 from whichthe “fingers” of slotted cylindrical ring 707 extend upward, e.g.,parallel to the Z-axis. Holes 731 are between the fingers of slottedcylindrical ring 707.

In addition, lens body 703 is surrounded by ring 709 which isparticularly inserted into cylindrical ring 707 of camera body 701 andcan be seen as well through slots 711 of slotted cylindrical ring 707.Ring 709 is effectively permanently attached to lens body 703 using anymethod available, e.g., glue, welding, friction, or integratedformation, and may be considered as a part of lens body 703 given thatsuch method of attachment is essentially not relevant to the process ofFIG. 6 or 6A for placing lens 705 into the ideal lens position and thenpermanently attaching camera body 701 and lens body 703.

FIG. 7B shows a cut through view of camera body 701 into which has beeninserted lens body 703. Also shown in FIG. 7B is sensor 713 fordetecting the infrared light. As can be seen better in FIG. 7B ring 709mates up against slotted cylindrical ring 707. This allows lens body 703to be moved up and down with respect to sensor 713, as well as tiltedwith respect thereto. By up and down it is meant translation alongZ-axis 719 of FIG. 7A, and by tilting it is meant rotation around X-axis715 of FIG. 7A and/or rotation around Y-axis 717 of FIG. 7A. Morespecifically, as seen from the enlarged detailed view of a portion ofcylindrical ring 707 and ring 709 shown in FIG. 7C, the surface of ring709 that mates against cylindrical ring 707, i.e., the distal surface ofring 709 with respect to the center of lens body 703, has a sphericalshape. Thus, distal surface of ring 709 may be considered to be asection of a spherical or ball joint and may be referred to herein asspherical ring 709. This facilitates the tilting of lens body 703 withrespect to sensor 713 and camera body 701. The proximal surface withrespect to the center of lens body 703 of spherical ring 709 may beshaped to match the shape of lens body 703 to which it is affixed, e.g.,cylindrical. Thus, this embodiment provides for three degrees of freedomof motion for lens body 703 with respect to camera body 701 prior togluing or welding.

The tightness of the mating between slotted cylindrical ring 707 andspherical ring 709 may be appropriate to the nature of the process bywhich lens body 703 will be ultimately permanently affixed to camerabody 701. For example, if glue is to be used, e.g., as described in FIG.6 , the tightness can be less than the tightness required for theprocess of FIG. 6A where glue is not used and instead friction betweenthe parts is relied on to keep the lens body 703 in place. Furthermore,for example, the tightness may be higher if the process of FIG. 6A isemployed and camera body 701 and lens body 703 are moved from the firstfixture in which the lens position is adjusted to the ideal lensposition to a second fixture at which the welding process is performed.Note that this is so because lens body 703 is held in position only byfriction and such can only be achieved with a tight fit.

Applicant has recognized that maintaining the lens in the ideal positiononce it has been achieved but before lens body 703 is sufficientlybonded to camera body 701 to prevent any motion thereof can be adelicate business and thus presents a particular challenge. This isbecause the forces applied to perform the bonding may cause a movementof lens 705 from the ideal position. In this regard it should beappreciated that the actuators that are used to move lens body 703 sothat lens 705 is placed into the ideal lens position are delicate andprecise and may typically be insufficient for simply holding lens body703 in place to overcome the forces that could be exerted by thebonding.

In particular, Applicant has recognized that to avoid moving lens 705from the ideal lens position that it should be endeavored in particularto avoid causing motion along Z-axis 719 of FIG. 7A. Thus, lineartranslation along the Z-axis as well as any tilting of lens body 703with respect to camera body 701 preferably should be avoided after theideal lens position has been achieved for lens 705.

To this end, Applicants have further recognized that when joining lensbody 703 to camera body 701 there should be as little as possible forceapplied as part of the joining process that could cause motion along theZ-axis, and preferably none. To this end, the bonding is performed so asto result in a minimal, if any, Z-axis component of force.

With regard to bonding by welding, movement of the lens may occur whenthere is a gap between slotted cylindrical ring 707 and spherical ring709 at the welding point. This is because the welded area shrinks and,due to the gap, this results in a force being exerted across where thegap was prior to the welding. Avoiding such a force may be achieved byperforming the welding in the vicinity of, and preferably right at, thetangent points of contact between slotted cylindrical ring 707 andspherical ring 709. By this it should be appreciated that given that thedistal surface of spherical ring 709 with respect to the center of lensbody 703 has a spherical shape, there will be, essentially, at least intheory, only a single circumference which is a cross section of thesphere that contacts the interior of slotted cylindrical ring 707 whenthe parts are made to mate with tight tolerances. Thus, the weldingshould be along this cross section circumference as it defines a tangentbetween slotted cylindrical ring 707 and spherical ring 709. Such atangent circumference can be conceptually visualized more easily in theview of FIG. 7C. Given that perfect precision to weld only exactly alongthe theoretical tangent circumference is, essentially, practically notpossible, the welding should be performed along the theoretical tangentcircumference line with the expectation that there will be someextension of the weld “above” and “below” the theoretical tangentcircumference that is consistent with manufacturing procedures andtolerances.

It should also be appreciated that sections of the entire tangent linemay not be visible, e.g., because they are hidden behind the “fingers”of slotted cylindrical ring 707, i.e., the portions of slottedcylindrical ring 707 that are not slots 711. Nevertheless, there is noneed for the portions of the tangent circumference that run behind the“fingers” of slotted cylindrical ring 707 to be visible in order toperform the welding along such portions. This is because the welding maybe performed through the “fingers” of slotted cylindrical ring 707 byheating to welding temperature the visible portion of slottedcylindrical ring 707 behind which the tangent circumference lies. Inthis regard, for example, a weld may be made through the aluminum thatmay make up slotted cylindrical ring 707, e.g., through 0.5 mm thickaluminum. Illustrative tangent points 733 of FIG. 7A are where thetangent circumference of spherical ring 709 becomes exposed, as itconceptually extends along slots 711, and where the junction of slottedcylindrical ring 707 meets the tangent circumference and so is alocation suitable for a weld point.

Slots 711 ease detecting the tangent circumference by providing visualor sensory access to at least part of spherical ring 709. In oneembodiment of the invention, computer vision may be employed to detectthe tangent circumference. In another embodiment of the invention,triangulation, e.g., using one or more distance sensors, is employed todetect the tangent circumference. Knowing where the tangentcircumference is enables the welding to be performed along it.

In the event the process of FIG. 6 is employed with glue, the glue maybe applied in accordance with the illustrative application shown in FIG.7D, which shows a top view camera body 701 and lens body 703. Morespecifically, glue dots 725 may preferably be applied in several ofslots 711 that are equally spaced around cylindrical ring 707, where 3dots are preferably the minimum number employed. Curing is preferablyperformed as soon as the lens is placed in the ideal lens position. Theglue dots so placed are expected to have minimal effect on the placementof lens 705 with respect to the ideal lens position in which it has beenplaced prior to curing. Also, the adhesive should be applied so as tobond a portion of slotted cylindrical ring 707 to a portion of sphericalring 709. While not necessarily required, the glue may be placed alongthe tangent circumference at the point where sides of the “fingers” ofslotted cylindrical ring 707 are exposed and the glue can reach thesides of the “fingers” of slotted cylindrical ring 707 and the portionof spherical ring 709 exposed by slots 711. In other words, the exposedarea of mating, e.g., the exposed area where there can be seen contactpoints suitable for gluing or welding, between slotted cylindrical ring707 and spherical ring 709 so that slotted cylindrical ring 707 andspherical ring 709 may be bonded together.

Good bonding is achievable because uncoated aluminum, of which slottedcylindrical ring 707 and spherical ring 709 may be made, reflects verywell the ultraviolet light typically employed for curing the glue. Insome embodiments the adhesive may be applied at any visible location atwhich a weld could be made. By so applying and curing the glue, in theevent the glue is of a type that shrinks, e.g., substantially, oncuring, the effect of shrinkage of the glue during curing on motion oflens 705 from its ideal position is reduced or eliminated as well.

The adhesive should be placed in enough areas so that after it is curedthe resulting structural strength will be enough to withstand thevarious forces that may be applied on the combined camera body and lensbody until welding is fully complete. After welding is fully complete,the adhesive strength is no longer relevant. Indeed, at that point theadhesive may even be removed in some embodiments.

Welding may be performed anywhere along the tangent circumference whereglue was not deployed. It may be advisable in some embodiments toinitially perform the welding at three areas that are evenly distributedaround cylindrical ring 707. Once camera body 701 and lens body 703 areadequately secured, e.g., by the welding alone or the welding incombination with the glue, additional welding can then be performedbeyond the tangent circumference line between ring 709 and slottedcylindrical ring 707. Such may be done, for example, to increasemechanical strength or provide for sealing between camera body 701 andlens body 703.

In other embodiments, e.g., following the process of FIG. 6A, when usingthe components of FIG. 7A, in lieu of first gluing, welding may beperformed initially in a number of limited locations, e.g., locationswhere glue would have been placed as described above in connection withthe process of FIG. 6 .

Connector 765 (FIG. 7A) may be used to deliver signals to and retrievesignals from the assembled infrared camera.

FIG. 8A shows another illustrative embodiment for use with the methodsof FIGS. 6 and 6A. This embodiment provides for five degrees of freedomof motion for lens body 703 with respect to camera body 701 prior togluing or welding. These include the same three degrees provided by theembodiment of FIG. 7A-7D along with planar motion, i.e., motion in the Xdirection and the Y direction which together form the X-Y plane which isthe plane of sensor 713.

In FIG. 8A, slotted cylindrical ring 707 of FIG. 7 has been replacedwith slotted cylindrical ring 807 which has longer sections, i.e.,longer “fingers” between the slots, i.e., slots 811, and also has lip orbase 821 which sits on camera body top 835 which is, in turn, on top ofcamera body 701. By slotted cylindrical ring 807 being formed with lip821 slotted cylindrical ring 807 can slide in the X-Y plane on top ofcamera body top 835. This can be seen more clearly in FIG. 8C whichshows an enlarged detailed view of the cut through view of camera body701 into which has been inserted lens body 703 that is shown in FIG. 8Bor in the exploded view of FIG. 8F.

In the embodiment of FIG. 8A, unlike the embodiment of FIG. 7A, slottedcylindrical ring 807 is not effectively permanently attached to camerabody 701. Instead, as noted above, slotted cylindrical ring 807 isinitially able to slide with respect to camera body top 835. Camera bodytop 835 is permanently attached to camera body 701 using any methodavailable, e.g., glue, welding, friction, or integrated formation, andmay be considered as a part of camera body 701 given that such method ofattachment is essentially not relevant to the process of FIG. 6 or 6Afor placing lens 705 into the ideal lens position and then permanentlyattaching camera body 701 and lens body 703.

In the event the process of FIG. 6 is employed, the glue noted thereinmay be applied in accordance with the illustrative application shown inFIG. 8D, which shows a top view camera body 701 and lens body 703. Morespecifically, glue dots 825 may preferably be applied in several ofslots 811 equally spaced around cylindrical ring 707, where 3 dots arepreferably the minimum number employed. This is to help prevent motionalong the Z-axis or tilt motion. In addition, glue dots 827 maypreferably be applied equally spaced around cylindrical ring 707 at theinterface of lip 821 and top of camera body 835, where 3 dots arepreferably the minimum number employed. This is to prevent planarmotion, i.e., motion along the X-Y plane. Curing is preferably performedas soon as the lens is placed in the ideal lens position. The glue dotsshould be placed so that any shrinkage of the glue during cure will haveminimal effect on the placement of lens 705 with respect to the ideallens position in which it has been placed prior to curing. The adhesivecan be applied on any two exposed parts and good bonding is achievablebecause uncoated aluminum, of which at least the relevant portions ofcamera body 701 and lens body 703 may be made, reflects very well theultraviolet light typically employed for curing the glue. It should beappreciated that the adhesive may be applied anywhere a weld could bemade except that a weld may be made through the aluminum that may makeup slotted cylindrical ring 807, e.g., through 0.5 mm thick aluminum,while adhesive may only be applied on outer surfaces. By so applying andcuring the glue, the effect of shrinkage of the glue during curing onmotion of lens 705 from its ideal position is reduced or eliminated aswell.

The adhesive should be placed in enough areas so that after it is curedthe resulting structural strength will be enough to withstand thevarious forces that may be applied on the combined camera body and lensbody until welding is complete. Welding of spherical ring 709 to slottedcylindrical ring 807 may then be performed in various ones of the areasalong the tangent circumference that do not have therein glue. Weldingmay be performed along the tangent circumference within ones of slots811 that do not contain glue and/or through the various fingers ofslotted cylindrical ring 807. In addition, welding may be performed atvarious locations around the perimeter of spherical ring 807 where lip821 meets camera body 701. After welding is complete, the adhesivestrength is no longer relevant. Indeed, at that point the adhesive mayeven be removed in some embodiments.

FIG. 8E shows the same view as FIG. 8A but with an illustrative exampleof the adhesive applied. FIG. 8F shows an exploded view of thecomponents of FIG. 8A. Before inserting lens body 703 into camera body701, spherical ring 709 is permanently affixed to lens body 703 andbecomes part thereof. Also, as noted above, camera body top 835 islikewise permanently affixed to camera body 701. Also as noted above, ascan be seen more easily in FIG. 8E, camera body top 835 may provide aplanar surface along which slotted cylindrical ring 807 can move.

In other embodiments, e.g., following the process of FIG. 6A, when usingthe components of FIG. 8A, in lieu of first gluing, welding may beperformed in the locations where glue would have been placed asdescribed above in connection with the process of FIG. 6 .

FIG. 9A shows another illustrative embodiment for use with the methodsof FIGS. 6 and 6A. This embodiment provides for the same three degreesof freedom of motion for lens body 703 with respect to camera body 701prior to gluing or welding as provided by the embodiment of FIG. 7A-7D.

Camera body top 935 is permanently attached to camera body 701 using anymethod available, e.g., glue, welding, friction, or integratedformation, and may be considered as a part of camera body 701 given thatsuch method of attachment is essentially not relevant to the process ofFIG. 6 or 6A for placing lens 705 into the ideal lens position and thenpermanently attaching camera body 701 and lens body 703. Spherical ring909 in turn is permanently attached to camera body top 935. This can bemore easily seen in the exploded view of FIG. 9D.

Slotted cylindrical ring 907 is permanently attached to lens body 703using any method available, e.g., glue, welding, friction, or integratedformation, and may be considered as a part of lens body 703 given thatsuch method of attachment is essentially not relevant to the process ofFIG. 6 or 6A for placing lens 705 into the ideal lens position and thenpermanently attaching camera body 701 and lens body 703. Note thatunlike the embodiment of FIG. 7 , slots 911 of slotted cylindrical ring907 do not extend upward substantially the whole height of slottedcylindrical ring 907 but rather only extend partially upward in thatthere is a solid band 923 above slots 911. Also, the “fingers” ofslotted cylindrical ring 911 extend downward from solid band 923.

Camera body 701 and lens body 703 are mated by having slottedcylindrical ring 907 be placed over spherical ring 909. Spherical ring909 is thus within slotted cylindrical ring 907 of lens body 703.Spherical ring 909 can be seen through slots 911 of slotted cylindricalring 907. This can be more easily visualized when looking at explodedview 9D.

FIG. 9B shows a cut through view of camera body 701 into which lens body703 has been inserted. Also shown in FIG. 9B is sensor 713 for detectingthe infrared light. As can be seen better in FIG. 9B, spherical ring 909mates up against slotted cylindrical ring 907. This allows lens body 703to be moved up and down with respect to sensor 713, as well as tilted,e.g., rotated around the X-axis and/or the Y axis with respect thereto.An enlarged detailed view of a portion of cylindrical ring 907 and ring909 is shown in FIG. 9C.

FIG. 9D shows an exploded view of the components of FIG. 9A. Asindicated above, before inserting lens body 703 into camera body 701spherical ring 709 is permanently affixed to camera body top 935 whichis in turn permanently affixed to camera body 701 and becomes partthereof. In addition, slotted cylindrical ring 907 is permanentlyaffixed to lens body 703 and becomes part thereof. Thus, spherical ring909 and slotted cylindrical ring 907 are arranged oppositely ofspherical ring 709 and slotted cylindrical ring 707 of FIG. 7A.

Although not shown in FIGS. 9A-9D, when performing the process of FIG. 6glue may be employed in various ones of slots 911 in the mannerdescribed hereinabove. Thereafter, welding may be performed anywherealong the tangent circumference where glue was not deployed in themanner described hereinabove. It may be advisable in some embodiments toinitially perform the welding at three areas that are evenly distributedaround cylindrical ring 907. Once camera body 701 and lens body 703 areadequately secured, e.g., by the welding alone or the welding incombination with the glue, additional welding can then be performedbeyond the tangent circumference line between spherical ring 909 andslotted cylindrical ring 907. Such may be done, for example, to increasemechanical strength or provide for sealing between camera body 701 andlens body 703.

In other embodiments, e.g., following the process of FIG. 6A, when usingthe components of FIG. 9A, in lieu of first gluing, welding may beperformed initially in a number of limited locations, e.g., locationsalong the tangent circumference where glue would have been placed asdescribed above in connection with the process of FIG. 6 .

FIG. 10A shows another illustrative embodiment for use with the methodsof FIGS. 6 and 6A. This embodiment provides for five degrees of freedomof motion for lens body 703 with respect to camera body 701 prior togluing or welding. These include the same three degrees provided by theembodiment of FIG. 7A-7D along with planar motion, i.e., motion in the Xdirection and the Y direction which together form the X-Y plane which isthe plane of sensor 713.

In FIG. 10A, slotted cylindrical ring 707 of FIG. 7 has been replacedwith solid cylindrical ring 1007. Solid cylindrical ring 1007, similarto slotted cylindrical ring 807 (FIG. 8A) has base or lip 1021 and so itcan slide over camera body top 835 in the X-Y plane on top of camerabody 701. More specifically, in the embodiment of FIG. 10A, unlike theembodiment of FIG. 7A, solid cylindrical ring 1007 is not effectivelypermanently attached to camera body 701. Instead, solid cylindrical ring1007 is initially able to slide with respect to camera body top 835.Camera body top 835 is permanently attached to camera body 701 using anymethod available, e.g., glue, welding, friction, or integratedformation, and may be considered as a part of camera body 701 given thatsuch method of attachment is essentially not relevant to the process ofFIG. 6 or 6A for placing lens 705 into the ideal lens position and thenpermanently attaching camera body 701 and lens body 703.

To this end, solid cylindrical ring 1007 has a lip or base 1021 that issimilar to lip 821 of the embodiment of FIG. 8 . Lip or base 1021, moreeasily seen in FIGS. 11B-11D, sits on camera body top 835 thus allowingsolid cylindrical ring 1007 to be able to initially slide over the X-Yplane on top of camera top 835 prior to being permanently affixed. Thiscan be seen more clearly in FIG. 10C which shows an enlarged detailedview of the cut through view of camera body 701 or in FIG. 10D whichshows an exploded view.

As in the embodiment of FIG. 7A, lens body 703 is surrounded byspherical ring 709. Spherical ring 709 is effectively permanentlyattached to lens body 703 using any method available, e.g., glue,welding, friction, or integrated formation, and may be considered as apart of lens body 703 given that such method of attachment isessentially not relevant to the process of FIG. 6 or 6A for placing lens705 into the ideal lens position and then permanently attaching camerabody 701 and lens body 703.

Cylindrical-spherical adapter 1041 is interposed between spherical ring709 and solid cylindrical ring 1007. As can be seen in FIG. 10B or 10C,the surface of cylindrical-spherical adapter 1041 that mates againstspherical ring 709, i.e., the proximal surface of cylindrical-sphericaladapter 1041 with respect to the center of lens body 703, has aspherical shape. This facilitates the tilting of lens body 703 withrespect to sensor 713 and camera body 701. The distal surface withrespect to the center of lens body 703 of cylindrical-spherical adapter1041 that mates against solid ring 1007 may be cylindrical in shape tomatch the shape of solid ring 1007.

Welding may be performed at 1) the exposed interface between sphericalring 709 and cylindrical-spherical adapter 1041, i.e., the circumferenceindicated by 1061, 2) the exposed interface betweencylindrical-spherical adapter 1041 and solid ring 1007, i.e., thecircumference indicated by 1063, and 3) the interface between solid ring1007 and camera body top 835, i.e., the circumference indicated by 1065.The welding may be performed continuously along each interface, i.e.,around the entire circumference, thus allowing for sealing by welding.In other words, such welding seals the internal area and it alsopermanently fixes the position of lens body 703 with respect to camerabody 701.

Because welding may be performed through exterior layers, welding mayalso be performed, or performed instead, anywhere along the interfacebetween spherical ring 709 and cylindrical-spherical adapter 1041, evenwhere not exposed, and also anywhere along the interface betweencylindrical-spherical adapter 1041 and solid ring 1007. This is alsopossible because the interface between spherical ring 709 andcylindrical-spherical adapter 1041 is spherical, and hence there is notangent circumference, and similarly, the interface betweencylindrical-spherical adapter 1041 and solid ring 1007 is cylindrical,and hence there is no tangent circumference.

As such, it should be appreciated that the use of cylindrical-sphericaladapter 1041 between spherical ring 709 and solid cylindrical ring 1007may provide several advantages.

The first advantage is the ability to have full contact between thesurfaces being welded. Such full contact may prevent unwanted movementduring welding, given that such unwanted movement might be caused bydeviations in the identification of the tangent line which is to bewelded. Indeed, such unwanted movement has been observed when welding isperformed above or below the tangent line and such unwanted movementmoves lens 705 from the ideal lens position. The full contact may makethe welded bond stronger, because it enables a massive continuous metalconnection between the two components instead of there being only onethin line of welding on the tangent line.

The second advantage which may be achieved by this arrangement isfreedom of the weld position in that welding may be performed on anyvisible area of the external part being welded. Such may also providefor the further advantage of allowing automatic welding which isperformed without the need to adjust the welding position.

The third advantage which may be achieved by this arrangement isprotection of the internal area, in particular, for example, protectionagainst heat or possible contamination by elements such as gas, smoke,and particles, that may develop during the welding process. In thisconfiguration, the welding is done at the external material and so thereis a solid barrier between the welding area and the internal area.

If implementing the process of FIG. 6 , glue may be placed along anumber of points, e.g., 3, around each of the interfaces. Ifimplementing the process of FIG. 6A, a few, e.g., three, spot weldssufficient to maintain the relative positional relationship between thelens body and the camera body without fully welding them may be made,e.g., along the interfaces. Alternatively, friction may be used to holdthe parts sufficiently together.

FIG. 11A shows another illustrative embodiment for use with the methodsof FIGS. 6 and 6A. This embodiment provides for five degrees of freedomof motion for lens body 703 with respect to camera body 701 prior togluing or welding. These include the same three degrees provided by theembodiment of FIG. 7A-7D along with planar motion, i.e., motion in the Xdirection and the Y direction which together form the X-Y plane which isthe plane of sensor 713.

The embodiment of FIG. 11A combines the approach of the embodimentsFIGS. 9A and 10A. By this it is meant that similar to the embodimentFIG. 9 the cylindrical ring 1107 is attached to lens body 703 andspherical ring 1109 is placed on camera body top 835 which in turn ispermanently attached to camera body 701 using any method available,e.g., glue, welding, friction, or integrated formation, and may beconsidered as a part of camera body 701 given that such method ofattachment is essentially not relevant to the process of FIG. 6 or 6Afor placing lens 705 into the ideal lens position and then permanentlyattaching camera body 701 and lens body 703.

In addition, similar to the embodiment FIG. 10A, cylindrical-sphericaladapter 1041 is employed to couple between solid cylindrical ring 1107and spherical ring 1109.

However, unlike the embodiment of FIG. 9A, spherical ring 1109 has a lipor base 1121, similar to lip 821 of the embodiment of FIG. 8 , whichsits on camera body top 835 and so spherical ring 1109 can initiallyslide over the X-Y plane on top of camera top 835 prior to beingpermanently affixed. This can be seen more clearly in FIG. 11C whichshows an enlarged detailed view of the cut through view of camera body701 or in FIG. 11D which shows an exploded view.

Similar to the embodiment of FIG. 10A, cylindrical-spherical adapter1041 is interposed between spherical ring 1109 and solid cylindricalring 1007. As can be seen in FIG. 11B or 11C, the surface ofcylindrical-spherical adapter 1041 that mates against spherical ring1109, i.e., the proximal surface of cylindrical-spherical adapter 1041with respect to the center of lens body 703, has a spherical shape. Thisfacilitates the tilting of lens body 703 with respect to sensor 713 andcamera body 701. The distal surface with respect to the center of lensbody 703 of cylindrical-spherical adapter 1041 that mates against solidring 1107 may be cylindrical in shape to match the shape of solid ring1107.

Welding may be performed at 1) the exposed interface between sphericalring 1109 and cylindrical-spherical adapter 1041, i.e., thecircumference indicated by 1161, 2) the exposed interface betweencylindrical-spherical adapter 1041 and solid ring 1107, i.e., thecircumference indicated by 1163, and 3) the interface between solid ring1107 and camera body top 835, i.e., the circumference indicated by 1165.The welding may be performed continuously along each interface, i.e.,around the circumference, thus allowing for sealing by welding. In otherwords, such welding seals the internal area and it also permanentlyfixes the position of lens body 703 with respect to camera body 701.

If implementing the process of FIG. 6 , glue may be placed along anumber of points, e.g., 3, around each of the interfaces. Ifimplementing the process of FIG. 6A, a few, e.g., three, spot weldssufficient to maintain the relative positional relationship between thelens body and the camera body without fully welding them may be made,e.g., along the interfaces.

Because welding may be performed through exterior layers, welding mayalso be performed, or performed instead, anywhere along the interfacebetween spherical ring 1109 and cylindrical-spherical adapter 1041, evenwhere not exposed, and also anywhere along the interface betweencylindrical cylindrical-spherical adapter 1041 and solid ring 1107. Thisis also possible because the interface between spherical ring 1109 andcylindrical-spherical adapter 1041 is spherical, and hence there is notangent circumference, and similarly, the interface betweencylindrical-spherical adapter 1041 and solid ring 1107 is cylindrical,and hence there is no tangent circumference.

FIG. 12A shows another illustrative embodiment for use with the methodsof FIGS. 6 and 6A. This embodiment provides for the same three degreesof freedom of motion for lens body 703 with respect to camera body 701prior to gluing or welding as provided by the embodiment of FIG. 7A-7D.

Unlike the embodiment of FIG. 9A a camera body top is not employed.Instead, spherical ring 1209, seen in FIG. 12D, is permanently attachedto camera body 701. To this end, spherical ring 1209 may have a lowerportion 1253 which is adapted to be affixed within camera body 701, ascan be seen in FIGS. 12B-12D, and an upper portion 1255 which has thespherical shape for its distal surface with respect to the center oflens body 703 as explained hereinabove.

Slotted cylindrical ring 907, e.g., as described in connection with FIG.9A, is permanently attached to lens body 703 using any method available,e.g., glue, welding, friction, or integrated formation, and may beconsidered as a part of lens body 703 given that such method ofattachment is essentially not relevant to the process of FIG. 6 or 6Afor placing lens 705 into the ideal lens position and then permanentlyattaching camera body 701 and lens body 703.

Camera body 701 and lens body 703 are mated by having slottedcylindrical ring 907 be placed over upper portion 1255 of spherical ring1209. Spherical ring 1209 is thus within slotted cylindrical ring 907 oflens body 703. Spherical ring 1209, and in particular upper portion 1255thereof, can be seen through slots 911 of slotted cylindrical ring 907in FIG. 12A. This can be more easily visualized in exploded view 12D.Also, FIG. 12B provides a cross sectional view and FIG. 12C is anenlarged view of the interface between spherical ring 1209 and slottedcylindrical ring 907.

Gluing may be performed within slots 911, as described hereinabove withregard to FIGS. 7A-7D. Welding may be performed along the tangentcircumference where there is not glue, as described hereinabove withregard to FIGS. 7A-7D.

FIG. 13A shows another illustrative embodiment for use with the methodsof FIGS. 6 and 6A. This embodiment provides for the same three degreesof freedom of motion for lens body 703 with respect to camera body 701prior to gluing or welding as provided by the embodiment of FIG. 7A-7D.

Camera body 701 contains slotted cylindrical ring 1307 which receivesinterior thereto lens body 703. Slotted cylindrical ring 1307 iseffectively permanently attached to camera body 701 using any methodavailable, e.g., glue, welding, friction, or integrated formation, andmay be considered as a part of camera body 701 given that such method ofattachment is essentially not relevant to the process of FIG. 6 or 6Afor placing lens 705 into the ideal lens position and then permanentlyattaching camera body 701 and lens body 703. Slotted cylindrical ring1307 is different from slotted cylindrical ring 707 in that slottedcylindrical ring 1307 has relatively long slots 1311 that extendhorizontally through slotted cylindrical ring 1307. Thus, slottedcylindrical ring 1307 can be thought of as being made up of uppercylindrical ring 1371, lower cylindrical ring 1373, and bridge supports1375.

In addition, lens body 703 is surrounded by spherical ring 709 which isparticularly inserted into cylindrical slotted ring 1307 of camera body701 and can be seen as well through slots 1311 of slotted cylindricalring 1307. Spherical ring 709 is effectively permanently attached tolens body 703 using any method available, e.g., glue, welding, friction,or integrated formation, and may be considered as a part of lens body703 given that such method of attachment is essentially not relevant tothe process of FIG. 6 or 6A for placing lens 705 into the ideal lensposition and then permanently attaching camera body 701 and lens body703. This can be more easily seen in exploded view 13E.

FIG. 13B shows a cut through view of camera body 701 into which has beeninserted lens body 703. Also shown in FIG. 13B is sensor 713 fordetecting the infrared light. FIG. 13C shows an enlarged detailed viewof the cut through view is shown in FIG. 13B.

In order to perform the method of FIG. 6 , e.g., step S610 thereof,adhesive dots 1377 are applied to lens housing 703 above the interfacewith spherical ring 709. When spherical ring 709 and lens body areinserted into camera body 701, by being inserted into cylindricalslotted ring 1307, this is done in a manner such that adhesive dots 1377make contact with upper cylindrical ring 1371. The calibration is thenperformed to bring lens 705 into the ideal lens position. Once lens 705is in the ideal lens position, the adhesive is cured. Once the glue iscured, welding, e.g., per step S640 of the process of FIG. 6 , may beperformed on the tangent circumference. Because the glue was applied onlens body 703 only above spherical ring 709 and only contacts uppercylindrical ring 1371 of cylindrical ring 1307, and lens body 703 wasinserted into camera body 701 such that spherical ring 709 is only incontact with lower cylindrical ring 1373, there is no glue in thevicinity of the tangent circumference. Hence, the welding may beperformed continuously along the tangent circumference, i.e., around theentire tangent circumference, thus allowing for sealing by welding. Suchwelding seals the internal area and permanently fixes the position oflens body 703 with respect to camera body 701.

FIG. 13D shows a top view of the embodiment with four illustrative gluedots being visible.

Slots 1311 ease detecting the tangent circumference by providing visualor sensory access to at least part of spherical ring 709. As notedabove, in one embodiment computer vision may be employed to detect thetangent circumference. In another embodiment of the invention,triangulation, e.g., using one or more distance sensors, is employed todetect the tangent circumference. Knowing where the tangentcircumference is enables the welding to be performed along it.

FIG. 14 shows a flow chart for an illustrative process by which thesensor is adjusted with respect to the lens, thus rendering the lens inthe ideal lens position, instead of moving the lens body, the camerabody, or both with respect to the other. With regard to the embodimentsdescribed above, this may be achieved by holding lens body 703 fixed andmoving camera body 701 with a robot arm, e.g., one coupled to a hexapod.

In some embodiments, when performing the process of FIG. 14 , the camerabody housing is not initially affixed to contain the sensor and otherelectronics but rather is later affixed. This way, internal componentscan be manipulated, e.g., by a robotic arm, to adjust the position ofthe sensor.

The process is entered in step 1400. In step S1410, the sensor isattached to the lens body, the sensor being in an initial position. Instep S1420, the position and orientation of the lens is adjusted so asto effectively bring the lens into the ideal lens position with respectto the adjusted position of the sensor. This may be performed by a robotarm under computer control using feedback from the sensor. In stepS1420, the ideal lens position is determined to be reach in a mannersimilar to that described above, for example, based on calibrationtarget images and MTF charts associated with those targets, e.g., asdiscussed in connection with FIG. 3 .

Once the lens is in the ideal lens position with respect to the sensor,a welding process is performed in step S1430 to fix the sensor at itsposition. In an embodiment, the welding process is performed by awelding unit that is computer controlled, i.e., controlled by softwareexecuting on a computer, or hardware, that is configured to control theoperation of the welding unit. Thereafter, in step S1440, the exteriorcamera body is attached to complete the camera. The camera alignment maybe verified in optional step S1450. In an embodiment, optional stepS1450 may be performed before step S1440.

FIG. 15 shows robotic arm 140 holding lens body 703. Also shown areillustrative welders 1549, e.g., laser welders. Although three laserwelders 1549 are shown, any number may be used. In one embodiment, laserwelders are maintained in a fixed position. In one embodiment, one ormore of laser welders 1549 may be used to perform spot welding to keeplens body 703 and camera body 701 positioned so that lens 705 is in theideal lens position. In one embodiment, one or more of laser welders mayperform the entire welding process, e.g., as called for in step S640 ofFIG. 6 or step S640A of FIG. 6A. To that end, camera body 701 and lensbody 703 may be moved, e.g., rotated. In one embodiment, one or more oflaser welders 1549 may be used to perform a welding process to fix theinfrared sensor into position, e.g., as called for in step S1430 (FIG.14 ).

FIG. 16 shows robotic arm 140 holding lens body 703. Also shown isillustrative welder 1549. Welder 1549 is attached to robotic arm 1663which is used to move welder 1549 with respect to camera body 701 andlens body 703. In one embodiment, laser welder 1549 may be used toperform spot welding to keep lens body 703 and camera body 701positioned so that lens 705 is in the ideal lens position. In oneembodiment, laser welder may perform the entire welding process, e.g.,as called for in step S640 of FIG. 6 or step S640A of FIG. 6A. To thatend, in addition to welder 1549 being moved by robotic arm 1663, camerabody 701 and lens body 703 may be moved, e.g., rotated. In oneembodiment, laser welder 1549 may be used to perform a welding processto fix the infrared sensor into position, e.g., as called for in stepS1430 (FIG. 14 ). Although only a single robotic arm 1663 and a singlelaser welder 1549 is shown, any number of robotic arms and laser weldersmay be employed.

FIG. 17A shows another illustrative embodiment for use with the methodof FIG. 14 , and particular, for holding lens body 703 fixed and movingsensor 713. This embodiment provides for five degrees of freedom ofmotion for sensor 713 with respect to lens body 703, and hence lens 705,prior to welding. These include the same three degrees provided by theembodiment of FIG. 7A-7D along with planar motion, i.e., motion in the Xdirection and the Y direction which together form the X-Y plane which isthe plane of sensor 713.

As can be better seen in the exploded view shown in FIG. 17C, sensor 713is attached to sensor mount disk 1769 which may be made of any materialsuitable for welding. Sensor 713 is attached to sensor mount disk 1769using any method available, e.g., glue or one or more fasteners, andsensor mount disk 1769 may be considered as a part of sensor 713, e.g.,a later affixed base thereof, given that such method of attachment isessentially not relevant to the process of fixing the position of sensor713. Sensor mount disk 1769 is employed because direct welding of sensor713 is often not possible or not recommended. In the event that sensor713 is constructed in a manner that it may be directly welded, thensensor mount disk 1769 need not be employed. Sensor mount disk 1769 ispositioned on the surface of slotted disk 1735. Sensor mount disk 1769may be moved in the X-Y plane, thus correspondingly moving sensor 713.Outer surface or rim 1709 of slotted disk 1735 has a spherical shape.Outer surface 1709 of slotted disk 1735 is thicker than the disk itselfso that it at least extends somewhat upwardly so as to contain movementin the X-Y plane of sensor mount disk 1769.

Slotted disk 1735 has slot 1787, through which is fed cable 1785 whichcarries signals to and from sensor 713. Slotted disk 1735 also has slots1789 through which fingers or jaws 1793 of robot arm gripper 1791, whichis in turn coupled to a robot arm, may be inserted. Although three slots1789 and three fingers 1793 are shown, such is for illustrative purposesonly as different numbers of fingers and slots may be employed.Typically the number of fingers 1793 and slots 1789 would match, howeverthat is not required. Fingers 1793 of the robot arm are further adaptedso as to grip and move sensor mount disk 1769 and hence sensor 713 inthe X-Y plane along the surface of slotted ring 1735. Robot arm gripper1791 is further adapted so as to tilt the surface of slotted disk 1735and hence both of sensor mount disk 1769 and sensor 713 which restthereon. In addition, robot arm gripper 1791 is further adapted so as tomove the surface of slotted disk 1735, and hence sensor mount disk 1769and sensor 713, with translation along the Z-axis. Thus, robot armgripper 1791 and its fingers 1793 can cause sensor 713 to be moved withrespect to lens 705 within lens body 703 until, effectively, lens 705 isin the ideal lens position with respect to sensor 713.

Inner surface 1799 of cylindrical-spherical adapter 1741, which matesagainst outer surface 1709 of slotted disk 1735, i.e., the proximalsurface of cylindrical-spherical adapter 1741 with respect to the centerof lens body 703, has a spherical shape. This facilitates the tilting ofslotted ring 1735 with respect to lens 705 and lens body 703. Outersurface 1707 of slotted disk 1735, i.e., the distal surface with respectto the center of lens body 703 of cylindrical-spherical adapter 1741, iscylindrical in shape.

Lens body 703 surrounds cylindrical-spherical adapter 1741.

Gripper 1797 holds lens body 703, and hence lens 705, in a fixedposition while robot arm gripper 1791 and its fingers 1793 move sensor703. Also shown is piston 1795 which exerts a force perpendicular to theslotted disk 1735, sensor mount disk 1769, and sensor 713, e.g., to holdthe parts together until they are welded.

FIG. 17D shows a further exploded view similar to FIG. 17C of anembodiment in robot arm gripper 1791 is mounted on computer-controlledhexapod 1745 which controls the movement of robot gripper 1791 andprovides for movement of robot gripper 1791 in all of the directionsnecessary to provide for the degrees of freedom for this embodiment.Thus, robot gripper 1791, its fingers 1793, piston 1795, and hexapod1745 act as a robotic arm to move and thereby adjust the position ofsensor 713 with respect to lens 705.

In other embodiments, other types of manipulators may be employed, e.g.,in lieu of hexapod 1745 and or in lieu of robot gripper 1791.

Welding may be performed, as shown in the cross section of FIG. 17Bat 1) at points on the interface between lens body 703 andcylindrical-spherical adapter 1741, i.e., points on the circumferenceindicated by 1757, 2) at points on the interface between slotted disk1735 and cylindrical-spherical adapter 1741, i.e., points on thecircumference indicated by 1758, and 3) the interface between sensormount disk 1769 and slotted disk 1735, i.e., the circumference indicatedby 1759. The welding may be performed by laser welder 1749. Becausethese welds are internal to the camera as a whole, the bonding theyprovide need not be as strong as in some other embodiments. Therefore,point welding may be sufficient. In one illustrative embodiment, threeweld points are employed. However, other numbers of welding points maybe employed and, where possible, the welding may be performedcontinuously along an interface, i.e., around the circumference.

FIG. 17B also shows spring 1798 employed with piston 1795, e.g., to keeppiston 1795 deployed.

FIG. 17E shows another slightly less exploded view than in FIG. 17Dwhere it can be seen that fingers 1791 extend through slots 1789 ofslotted disk 1735 to grab sensor mount disk 1769 which is thereon. Itcan also be seen that cable 1785 extends through slot 1787.

FIG. 17F shows an enlarged cross section of slotted disk 1735 havingmounted thereon sensor mount disk 1769 and in turn sensor 713. Fingers1793 of robot arm gripper 1791 can be seen inserted through slots 1789to grab sensor mount disk 1769 and thus effectively sensor 713. Thus, intotal, the combined robot arm can position sensor 713 relative to lens705 with five degrees of freedom.

After welding, exterior camera body 701 may be attached to lens body703. Advantageously, since all of the welding is performed internal tothe attached camera body, the camera body and lens body may becompletely sealed. In one embodiment, this is achieved by screw togethermating between camera body 701 and lens body 703, which, advantageously,provides for effective, easy to implement, and inexpensive attachment.

Note that not all components are visible in each cross section becauseof the plane in which the cross section is taken.

It will be appreciated by those of ordinary skill in the art that inmany of the embodiments disclosed herein an additional degree offreedom, namely, rotation about the Z-axis is possible. However, suchrotation has no effect on the ideal lens position, and as such may be,effectively, ignored.

The foregoing may be similarly applied to use with non-infrared cameras.

Portions of the various embodiments disclosed herein can be implementedas hardware, firmware, software, or any combination thereof. Moreover,the software is preferably implemented as an application programtangibly embodied on a program storage unit or computer readable mediumconsisting of parts, or of certain devices and/or a combination ofdevices. The application program may be uploaded to, and executed by, amachine comprising any suitable architecture. Preferably, the machine isimplemented on a computer platform having hardware such as one or morecentral processing units (“CPUs”), a memory, and input/outputinterfaces. The computer platform may also include an operating systemand microinstruction code. The various processes and functions describedherein may be either part of the microinstruction code or part of theapplication program, or any combination thereof, which may be executedby a CPU, whether or not such a computer or processor is explicitlyshown. In addition, various other peripheral units may be connected tothe computer platform such as an additional data storage unit and aprinting unit. Furthermore, a non-transitory computer readable medium isany computer readable medium except for a transitory propagating signal.

As used herein, the phrase “at least one of” followed by a listing ofitems means that any of the listed items can be utilized individually,or any combination of two or more of the listed items can be utilized.For example, if a system is described as including “at least one of A,B, and C,” the system can include A alone; B alone; C alone; A and B incombination; B and C in combination; A and C in combination; or A, B,and C in combination.

All examples and conditional language recited herein are intended forpedagogical purposes to aid the reader in understanding the principlesof the disclosed embodiment and the concepts contributed by the inventorto furthering the art, and are to be construed as being withoutlimitation to such specifically recited examples and conditions.Moreover, all statements herein reciting principles, aspects, andembodiments of the disclosed embodiments, as well as specific examplesthereof, are intended to encompass both structural and functionalequivalents thereof. Additionally, it is intended that such equivalentsinclude both currently known equivalents as well as equivalentsdeveloped in the future, i.e., any elements developed that perform thesame function, regardless of structure.

Unless otherwise explicitly specified herein, any lens shown and/ordescribed herein may actually be implemented as an optical system havingthe particular specified properties of that lens. Such an optical systemmay be implemented by a single lens element but is not necessarilylimited thereto. This is because, as is well known in the art, variousoptical systems may provide the same functionality of a single lenselement but in a superior way, e.g., with less distortion. Also, unlessotherwise explicitly specified here, all optical elements or systemsthat are capable of providing specific function within an overallembodiment disclosed herein are equivalent to one another for purposesof the present disclosure.

What is claimed is:
 1. A system for securing an infrared camera lens inoptical alignment with a multiple pixel infrared camera sensor,comprising: a computer-controlled robotic arm adapted to adjust arelative position of the infrared camera sensor and the infrared cameralens so as to bring the infrared lens into an ideal lens position withrespect to the infrared camera sensor, wherein the ideal lens positionis determined based on focus sharpness over at least a plurality ofpixels at the infrared camera sensor of at least one projectedcalibration target as focused by the infrared camera lens on theinfrared camera sensor; and at least one computer-controlled welder, theat least one computer-controlled welder being adapted to perform weldingtogether of at least two metal parts of the infrared camera after theinfrared camera lens is positioned by the robotic arm in the ideal lensposition with respect to the infrared camera sensor such that theinfrared camera lens is permanently maintained in the ideal lensposition.
 2. The system of claim 1, wherein the adjusting is performedby at least one of (i) moving a lens body containing the infrared cameralens with respect to a camera body containing the infrared camerasensor, and (ii) moving the infrared camera sensor with respect to theinfrared camera lens, the infrared camera lens being contained withinthe lens body, wherein the moving is not restricted to be within atwo-dimensional plane, the lens body and the camera body being at leasttwo of the at least two parts to be welded together by thecomputer-controlled welder.
 3. The system of claim 1, wherein theprojected calibration target is determined based on infrared rays outputby at least one collimator that is positioned such that the outputinfrared rays converge on the infrared camera sensor after passingthrough the infrared camera lens; and wherein the at least onecollimator includes a black body configured as the calibration target,and wherein the robotic arm is further configured to adjust the relativeposition based on a modulation transfer function (MTF) chart associatedwith the calibration target.
 4. The system of claim 1, wherein at leastone of the at least one computer-controlled welder is a laser welder. 5.The system of claim 1, wherein the at least one computer-controlledwelder performs the welding on at least a portion of tangentcircumference at an interface of a spherical shaped ring that is withina cylindrical shaped ring, at least one of the spherical shaped ring andthe cylindrical shaped ring being associated with a camera body and theother of the at least one of the spherical shaped ring and thecylindrical shaped ring being associated with a lens body containing theinfrared camera lens.
 6. The system of claim 1, wherein after beingplaced in the ideal lens position the infrared camera lens is kept inthe ideal lens position by the at least one computer-controlled welderfirst performing a plurality of spot welds as part of the welding. 7.The system of claim 1, wherein at least one of the at least onecomputer-controlled welder is mounted on a computer-controlled roboticarm.
 8. The system of claim 1, wherein the metal of at least one of thetwo metal parts comprises aluminum.
 9. The system of claim 1, whereinthe computer-controlled robotic arm is adapted to adjust the relativeposition by moving at least one of the infrared camera sensor and theinfrared camera lens in more than two degrees of freedom.
 10. A methodfor securing an infrared camera lens in optical alignment with amultiple pixel infrared camera sensor, comprising: adjusting a relativeposition of the infrared camera sensor and the infrared camera lens bycomputer-controlled robotic arm so as to bring the infrared lens into anideal lens position with respect to the infrared camera sensor, whereinthe ideal lens position is determined based on focus sharpness over atleast a plurality of pixels at the infrared camera sensor of at leastone projected calibration target as focused by the infrared camera lenson the infrared camera sensor; and welding together, by at least onecomputer-controlled welder, at least two metal parts of the infraredcamera after the infrared camera lens is positioned by the robotic armin the ideal lens position with respect to the infrared camera sensorsuch that the infrared camera lens is permanently maintained in theideal lens position.
 11. The method of claim 10, wherein the adjustingis performed by at least one of (i) moving a lens body containing theinfrared camera lens with respect to a camera body containing theinfrared camera sensor, and (ii) moving the infrared camera sensor withrespect to the infrared camera lens, the infrared camera lens beingcontained within the lens body, wherein the moving is not restricted tobe within a two-dimensional plane, the lens body and the camera bodybeing at least two of the at least two parts to be welded together bythe computer-controlled welder.
 12. The method of claim 10, wherein theprojected calibration target is determined based on infrared rays outputby at least one collimator that is positioned such that the outputinfrared rays converge on the infrared camera sensor after passingthrough the infrared camera lens; and wherein the at least onecollimator includes a black body configured as the calibration target,and wherein the robotic arm is further configured to adjust the relativeposition based on a modulation transfer function (MTF) chart associatedwith the calibration target.
 13. The method of claim 10, wherein atleast one of the at least one computer-controlled welder is a laserwelder.
 14. The method of claim 10, wherein the at least onecomputer-controlled welder performs the welding on at least a portion oftangent circumference at an interface of a spherical shaped ring that iswithin a cylindrical shaped ring, at least one of the spherical shapedring and the cylindrical shaped ring being associated with a camera bodyand the other of the at least one of the spherical shaped ring and thecylindrical shaped ring being associated with a lens body containing theinfrared camera lens.
 15. The method of claim 10, wherein after beingplaced in the ideal lens position the infrared camera lens is kept inthe ideal lens position by the at least one computer-controlled welderfirst performing a plurality of spot welds as part of the welding. 16.The method of claim 10, wherein at least one of the at least onecomputer-controlled welder is mounted on a computer-controlled roboticarm.
 17. The method of claim 10, wherein the metal of at least one ofthe two metal parts comprises aluminum.
 18. The method of claim 10,wherein the computer-controlled robotic arm is adapted to adjust therelative position by moving at least one of the infrared camera sensorand the infrared camera lens in more than two degrees of freedom.
 19. Amethod for securing a camera lens in optical alignment with a multiplepixel camera sensor, comprising: adjusting a relative position of thecamera sensor and the camera lens by computer-controlled robotic arm soas to bring the lens into an ideal lens position with respect to thecamera sensor, wherein the ideal lens position is determined based onfocus sharpness over at least a plurality of pixels at the camera sensorof at least one projected calibration target as focused by the cameralens on the camera sensor; and welding together, by at least onecomputer-controlled welder, at least two metal parts of the camera afterthe camera lens is positioned by the robotic arm in the ideal lensposition with respect to the infrared camera sensor such that the cameralens is permanently maintained in the ideal lens position.
 20. Themethod of claim 19, wherein the at least one computer-controlled welderperforms the welding on at least a portion of tangent circumference atan interface of a spherical shaped ring that is within a cylindricalshaped ring, at least one of the spherical shaped ring and thecylindrical shaped ring being associated with a camera body and theother of the at least one of the spherical shaped ring and thecylindrical shaped ring being associated with a lens body containing theinfrared camera lens.